Method for fixing a reinforcing mesh to a base or to the ground

ABSTRACT

Method of providing a reinforced substrate includes providing a base layer, providing a reinforcing mesh on the base layer and providing an adhesive strip. The adhesive strip includes an adhesive and a backing covering the adhesive. The adhesive strip is put on at least a portion of the reinforcing mesh, and force is applied to the adhesive strip to adhere the adhesive strip to the base layer and to the reinforcing mesh, so that the reinforcing mesh is secured to the base layer. The resultant reinforced substrate may include a reinforcing mesh having longitudinal and transverse wires which are surrounded by a solid adhesive on the adhesive strip to reduce or eliminate movement of the reinforcing mesh during the making of the reinforced substrate.

FIELD OF THE INVENTION

The invention relates to a method for applying a substrate. Morespecifically, the invention relates to a method for securing areinforcing element on a base or on the ground to reinforce a substrate.Even more particularly, the invention relates to a system and method foradhering a reinforcing element, such as a reinforcing mesh to the groundor to a base layer, such as a layer including a hydrocarbon-containingmaterial or the like, and then adding a substrate which is thusreinforced.

BACKGROUND OF THE INVENTION

Reinforcing roads or surfaces, such as parking lots, with wire mesh isknown.

A reinforcing mat or mesh which has been used for reinforcing the groundor a layer of the road that is made of asphalt, bitumen, or otherhydrocarbon-containing material, and the like, includes the successfulreinforcing mat sold by the N. V. Bekaert S.A. under the name MESHTRACK™. MESH TRACK™ includes a woven galvanized steel wire mat or mesh.

Methods of securing a reinforcing mat in such roads have been describedin:

Published European Patent Application No. 0 429 106 to N. V. BekaertS.A., published May 29, 1991; and

Published European Patent Application No. 0 505 010 to N. V. BekaertS.A., published Sep. 23, 1992.

N. V. Bekaert S.A. is likewise the assignee of U.S. Pat. No. 6,168,118to Vancraeynest et al., issued Jan. 2, 2001.

U.S. Pat. No. 4,074,948 to Heater, Jr., issued Feb. 21, 1978, entitled“Pavement Mat Process,” is likewise known.

OBJECTS AND SUMMARY OF THE INVENTION

It is an object of the invention to overcome the drawbacks of the priorart systems, methods, and devices.

It is another object of the invention to provide a system and method ofreinforcing asphalt and the like that is easier and faster to apply thanthe prior art.

A further object of the invention is to provide a method of attaching asubstrate to an underlying base, such as a base of concrete or asphalt.

Another object of the invention is to provide a method of attaching asubstrate, including a mesh, to an underlying base that uses a roll ofmaterial, such as asphalt, as an adhesive.

A further object of the invention is to provide a method of securing areinforcing element, such as a mesh, to an underlying base thatsufficiently secures the reinforcing element so that forces applied byan asphalt paving machine when applying asphalt over the reinforcingelement do not move the reinforcing element, such as by lifting up themesh.

It is another object of the invention to provide a system and method ofreinforcing asphalt and the like that can be evenly and consistentlyapplied.

It is a further object of the invention to provide a mesh or mat, suchas a wire mesh, which can be embedded in a base layer, such as theground or the existing asphalt layer, and which cannot be pulled throughthe securing material which secures the mesh to the existing layer.

Another object of the invention is to provide a system and method whichrequire no on-site heating of a liquid or solid adhesive, nor the use ofa liquid adhesive on-site, for example.

Yet another object of the invention is to provide a system and method ofsecuring a reinforcing mesh or mat that are faster than known methods.

It is another object of the invention to provide a system and method ofreinforcing a layer of asphalt on a base layer that includes a meshconfigured and engineered so that even if the mesh is movedlongitudinally or transversely under forces applied to a securing layeror element during installation, the securing layer will not loosen orcome up, even if the mesh is moved relative to the base layer.

It is yet another object of the invention to provide a system or methodof securing a mesh for reinforcing a layer of material, such as anasphalt material, which cannot be loosened, such as by substantiallyvertically applied forces pulling on an adhering mesh or an adheringlayer which secures the mesh to an existing layer, such as by one, two,or more workers pulling up on the mesh and/or adhering mesh securing thereinforcing mesh to the existing layer.

It is another object of the invention to provide a system and method forsecuring a mesh to a layer, such as a layer of asphalt, which requiresno curing time for such an adhesive layer.

Another object of the invention is to provide a method and system ofsecuring a mesh for reinforcing a layer of material, such as a layer ofasphalt, that require no fasteners, such as mechanical fasteners.

In sum, the invention is directed to a method for reinforcing a layer ofmaterial, such as an asphalt layer, including providing a bottom layerof material, providing a mesh on the bottom layer of the material,providing an adhesive strip of the type including a backing and anadhesive material on the backing, placing the adhesive strip on themesh, applying a force to the adhesive strip sufficient to secure theadhesive strip sufficiently to the bottom layer and sufficiently tosecure the mesh relative to the bottom layer, and then adding a toplayer of material, such as an asphalt layer.

The invention likewise includes a reinforced layer of material, such asan asphalt material, including a base layer, a reinforcing mesh, anadhesive strip adhering the mesh to the base layer, and a top layer ofmaterial, such as asphalt.

The invention likewise includes a reinforcing element, such as a meshwhich may be in the form of a metal, steel, galvanized steel, polymergrid, polymer reinforcing plastic, other plastics, and with or withoutadditional materials, backings, layers, mesh configurations, and otherinterlayer products.

It will be appreciated that relative terms such as up, down, top,bottom, left, and right, are for convenience only and are not intendedto be limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top front perspective view of an adhesive strip which may beused for fixing a reinforcing mesh to a base layer or to the ground,according to the invention;

FIG. 2 is a top front perspective view showing the first steps of themethod for fixing a reinforcing mesh to a base layer or to the groundaccording to the invention, in which the adhesive strip of FIG. 1 isbeing rolled out onto a reinforcing element, such as the illustratedreinforcing mesh;

FIG. 3 is a top front perspective view of further steps according to themethod for fixing a reinforcing mesh to a base layer or to the groundaccording to the invention, in which the adhesive strip of FIGS. 1 and 2is being further adhered to the reinforcing mesh and the base layer orthe ground;

FIG. 4 is a top front perspective view showing a still further step inthe method for fixing a reinforcing mesh to a base layer or to theground according to the invention, in which a further substrate, such asasphalt or another hydrocarbon-containing material is being applied tothe secured adhesive strip which secures the reinforcing mesh to thebase layer or to the ground, in accordance with the invention; and

FIG. 5 is a front elevational cross sectional view of the reinforcedsubstrate according to the invention, taken along 5-5 of FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

Turning to FIGS. 1-5, the system, method, and reinforced substrateaccording to the invention will be described in greater detail.

FIG. 1 shows an adhesive strip 10 which may be used in accordance withthe invention. Adhesive strip 10 may include an adhesive or reinforcinglayer 14. Adhesive layer 14 may include an adhesive or adhesive layer 22provided on a substantially nonadhesive layer or backing 26. Layer orbacking 26 may be made of a fabric, such as a synthetic fabric, whichmay be a nonwoven synthetic fabric, such as a felt.

For convenience, and depending on the degree of “stickiness” or adhesivecapabilities of adhesive layer 22 required, in use, a removable layer30, such as a peel-off backing 30, may be provided on adhesive layer 26.It will be appreciated that peel-off backing 30 may be provided on aside of adhesive layer 22 opposite to the side of adhesive layer 22 onwhich the backing 26 is provided. A leading edge 32 of backing 30 isshown partially peeled off.

In use, as shown in FIG. 2, initial steps 50 of securing, such as byadhering, a reinforcing element, such as a reinforcing mesh 60 may beseen.

Reinforcing mesh 60 may be in the form of a hexagonal mesh includinglongitudinal reinforcing elements or wires 64 and transversely extendingreinforcing elements or wire 68 extending transversely relative tolongitudinal wire 64.

First, a base, the ground, or other substrate 80 is provided orselected.

Then, the reinforcing mesh 60 may be placed on base layer 80, such as bylaying the reinforcing mesh 60 on top, as shown, or by rolling out thereinforcing mesh in the case where reinforcing mesh 60 is provided inrolls.

Depending on the manner in which reinforcing mesh 60 is supplied,reinforcing mesh 60 may or may not be further smoothed or “flattenedout” on top of base layer 80.

In order to secure mesh 60 relative to base layer 80, the user thenprovides securing or adhering element or adhesive layer 10 on top ofmesh 60 and base layer 80; i.e. on the side of reinforcing mesh 60opposite to base layer 80, as will be readily appreciated fromconsidering FIGS. 2-5, for example.

In the case where the adhesive layer or strip 10 is provided in the formof a roll 90, backing 30 may be removed at the same time roll 90 isunrolled on top of reinforcing mesh 60 in order to secure mesh 60 tobase 80. That is, a free edge 94 of peel-off layer 30 may be pulled awayfrom roll 90, as shown, as roll 90 is unrolled in the direction of arrow100. Needless to say, adhesive layer 22 may face mesh 60, as shown,during the unrolling process, depending on the intended use.

As will be appreciated from FIG. 3, in which the adhesive strip has beencompletely unrolled as a substantially flat strip 110, the nonadhesiveor substantially nonadhesive backing 26 will face upwardly away frommesh 60.

If desired, the adhesive strip and, specifically, adhesive layer 22thereof, may be pressed against reinforcing mesh 60 and bottom layer 80with sufficient additional force to ensure that reinforcing element ormesh 60 is substantially prevented from being moved relative to baselayer 80. That is, the adhesive of adhesive layer 22 and the degree towhich adhesive layer 22 is pressed against bottom 80 may be selected sothat reinforcing strip is retained in a desired location andconfiguration relative to the other components, such as bottom layer 80,and depending on the intended use, a top layer of material to be addedonto bottom layer 80, reinforcing mesh 60, and reinforcing strip 14, sothat the method of providing a reinforced substrate may be completed inthe desired fashion with the desired physical characteristics.

Thus, for example, the user may simply apply a downward force directingforces on top of backing 26 during the step of unrolling roll 90, suchas shown in FIG. 2, or the user may walk or otherwise apply downwardforces on backing 26 to secure adhesive layer 22 to reinforcing mesh 60and bottom 80, or the user may, for example, apply even greater forcesto strip 14, such as by use of the wheel of a vehicle driving one ormore times on top of backing 26 when backing 26 is in place as shown inFIG. 3, or the user may make use of a roller, such as illustrated by aroller 120 of FIG. 3 being rolled in a direction 130 along and on top ofbacking 26 so that forces are applied downwardly on adhesive strip 14 toensure that adhesive layer 22 is sufficiently secured to base 80 andreinforcing mesh 60 to achieve the desired physical characteristicsdescribed above.

After sufficient downward forces have been applied to backing 26, suchas shown in FIG. 4, depending on the thickness of adhesive layer 22 andbacking 26, some or all of portions of reinforcing mesh 60 covered bystrip 10 may be visible, owing to adhesive layer 22 having been forceddown securely against reinforcing mesh 60 and base layer 80.

The adhesive 22 may be selected so that adhesive strip may be applied tomesh 60 at ambient temperature; i.e., without preheating adhesive layer22 on-site.

As will be appreciated by viewing FIG. 4, a further layer 150, such as ahydrocarbon-containing layer, a bituminous layer, an asphalt layer, or abitumen material, for example, may be provided on top of each of mesh60, base 80, and adhesive strip 14.

Further layer 150 may be provided as soon as desired on top of mesh 60,base 80, and strip 10, thanks to there being no need to wait foradhesive layer 22 to cool, dry, or otherwise harden to adhere to mesh 60and base layer 80.

In the cross sectional view of FIG. 5 it will be appreciated that base80 may be an existing substrate, such as an existing asphalt layer, andthe like, which has been provided on an existing ground layer orconcrete layer 140, for example.

The reinforcing mesh may be made of metal, such as galvanized steel,plastic, and other materials, and may be made in accordance with U.S.Pat. No. 6,168,118 to Vancraeynest et al., issued Jan. 2, 2001, which isincorporated herein by reference. The reinforcing mesh may be thereinforcing supplied by N. V. Bekaert S.A., such as PAVETRAC® mesh.

The adhesive layer or strip may be made to include an adhesive layercomprising asphalt or bituminous materials. The asphalt base compoundmay be extruded onto a geotextile backing; e.g. a nonwoven polypropylenefabric, and the non-stick backing layer may be a removable thin plasticlayer. It is further contemplated that the nonwoven fabric may be anonwoven (needle felt) polypropylene layer. The non-adhesive fabricbacking may be thicker than the adhesive layer, depending on theintended use. The adhesive may be a solid selected to substantiallysurround wires of a reinforcing mesh, in use.

The adhesive strip may be as supplied under the name TracTac, a productof Pavetech International (see e.g. www.pavetech-intl.com).

While this invention has been described as having a preferred design, itis understood that it is capable of further modifications, and usesand/or adaptations of the invention and following in general theprinciple of the invention and including such departures from thepresent disclosure as come within the known or customary practice in theart to which the invention pertains, and as may be applied to thecentral features hereinbefore set forth, and fall within the scope ofthe invention or limits of the claims appended hereto.

1. A method of reinforcing a substrate to provide a reinforcedsubstrate, the method comprising: a) providing a base layer; b)providing a reinforcing mesh on the base layer; c) providing an adhesivestrip, the adhesive strip including a substantially solid adhesive and abacking substantially covering the adhesive; d) providing the adhesivestrip on at least a portion of the reinforcing mesh; e) applying asufficient force to the adhesive strip to sufficiently adhere theadhesive strip to the base layer and to sufficiently adhere the adhesivestrip to the reinforcing mesh, and the reinforcing mesh beingsufficiently secured to the base layer, so that before and during a stepof providing the substrate on the base layer and the adhesive strip, thereinforcing mesh and the adhesive strip remain in place relative to thebase layer; and f) providing the substrate on the adhesive strip and onthe reinforcing mesh secured to the base layer by the adhesive strip toprovide the reinforced substrate.
 2. A method as in claim 1, wherein: a)the base layer includes an existing hydrocarbon-containing layer.
 3. Amethod as in claim 2, wherein: a) the substrate includes ahydrocarbon-containing layer.
 4. A method as in claim 1, wherein: a) thesubstrate includes a hydrocarbon-containing layer.
 5. A method as inclaim 4, wherein: a) the reinforcing mesh includes a metal mesh.
 6. Amethod as in claim 5, wherein: a) the metal mesh includes a hexagonalmesh including longitudinal wires and transverse reinforcing wiresextending transversely relative to the longitudinal wires.
 7. A methodas in claim 6, wherein: a) the backing of the adhesive strip includes asynthetic fabric, and the adhesive of the adhesive strip includes anasphalt layer.
 8. A method as in claim 1, wherein: a) the backing of theadhesive strip includes a synthetic fabric, and the adhesive of theadhesive strip includes an asphalt layer.
 9. A method as in claim 1,wherein: a) the adhesive strip is provided on the at least a portion ofthe reinforcing strip at ambient temperature.
 10. A method as in claim9, wherein: a) the adhesive strip includes a removable backing providedon the asphalt layer.
 11. A method as in claim 1, wherein: a) thereinforcing mesh includes longitudinal and transverse reinforcing wires;and b) the step of applying a sufficient force to the adhesive layerincludes applying a sufficiently strong force to cause the substantiallysolid adhesive to substantially surround the longitudinal and transversewires of the reinforcing mesh.
 12. A method as in claim 1, wherein: a)in said step of providing an adhesive strip, the adhesive strip issupplied in a roll, and the rolled adhesive strip is unrolled onto thereinforcing mesh.
 13. A method as in claim 12, wherein: a) in said stepof applying a sufficient force, a roller is used to provide thesufficient force to adhere the adhesive strip to the base layer.
 14. Areinforced substrate, comprising: a) a base layer; b) a reinforcing meshon the base layer, the reinforcing mesh including longitudinal andtransverse wires; c) an adhesive strip, the adhesive strip including asubstantially solid adhesive and a backing substantially covering theadhesive; d) the adhesive strip being provided on at least a portion ofthe reinforcing mesh; e) the adhesive strip adhering to the base layerand adhering to the reinforcing mesh, and substantially surrounding thelongitudinal wires of the reinforcing mesh and adhering the reinforcingmesh to the base layer; and f) the substrate substantially surroundingthe adhesive strip and the reinforcing mesh secured to the base layer bythe adhesive strip.
 15. A reinforced substrate as in claim 14, wherein:a) the base layer includes an existing hydrocarbon-containing layer. 16.A reinforced substrate as in claim 15, wherein: a) the substrateincludes a hydrocarbon-containing layer.
 17. A reinforced substrate asin claim 14, wherein: a) the substrate includes a hydrocarbon-containinglayer.
 18. A reinforced substrate as in claim 17, wherein: a) thereinforcing mesh includes a metal mesh.
 19. A reinforced substrate as inclaim 18, wherein: a) the metal mesh includes a hexagonal mesh.
 20. Areinforced substrate as in claim 19, wherein: a) the backing of theadhesive strip includes a synthetic fabric, and the adhesive of theadhesive strip includes an asphalt layer.
 21. A reinforced substrate asin claim 14, wherein: a) the backing of the adhesive strip includes asynthetic fabric, and the adhesive of the adhesive strip includes anasphalt layer.
 22. A reinforced substrate as in claim 21, wherein: a)the adhesive is substantially solid and adhesive at ambient temperature.23. A method, as in claim 22, wherein: a) the hydrocarbon-containinglayer includes an asphalt layer which is substantially solid at ambienttemperature.
 24. A method of attaching a reinforcing mesh, the methodcomprising: a) providing a base layer; b) providing a reinforcing meshon the base layer; c) providing an adhesive strip, the adhesive stripincluding a substantially solid adhesive and a backing substantiallycovering the adhesive; d) providing the adhesive strip on at least aportion of the reinforcing mesh; e) applying a sufficient force to theadhesive strip to sufficiently adhere the adhesive strip to the baselayer and to sufficiently adhere the adhesive strip to the reinforcingmesh, and the reinforcing mesh being sufficiently secured to the baselayer, so that before and during a step of providing a substrate on thebase layer and the adhesive strip, the reinforcing mesh and the adhesivestrip remain in place relative to the base layer.
 25. A method as inclaim 24, wherein: a) the base layer includes an existinghydrocarbon-containing layer.
 26. A method as in claim 25, wherein: a)the reinforcing mesh includes a metal mesh.
 27. A method as in claim 24,wherein: a) the backing of the adhesive strip includes a syntheticfabric, and the adhesive of the adhesive strip includes an asphaltlayer.
 28. A method as in claim 24, wherein: a) the adhesive strip isprovided on the at least a portion of the reinforcing strip at ambienttemperature.